JP6772292B2 - Laminated molded product and its manufacturing method - Google Patents

Description

The present disclosure relates to a laminated molded product and a method for producing the same.

In recent years, decorated processed products have been used in fields such as the automobile industry and the clothing industry.

Quilting occupies an important position as one of the decoration methods to express a three-dimensional effect, and plays a role of adding commercial value by enhancing the design, especially in the interior parts and furniture of vehicles such as automobiles. .. For example, the prior art in the case of manufacturing using leather for an automobile seat is as follows. First, leather tanned with chrome (cowhide, etc.) is prepared as a skin material, and after laminating it with a cushioning material such as urethane foam and a thermoplastic adhesive sheet, or by stacking the skin material and cushioning material. After sewing the surroundings together and stopping, sew with a sewing machine according to the devised design. The cushioning material is compressed and thinned to form a concave portion in the sewn portion, and the portion surrounded by the sewn portion becomes a convex portion because the thickness of the cushioning material does not change, and a three-dimensional effect is expressed. Diamond patterns and border patterns are often used as such designs.

For example, Patent Document 1 below proposes a quilting processing method using an adhesive. This processing method is for quilting processing consisting of woven fabric with cushioning material (cushioning material) such as urethane, sponge, synthetic cotton, palm lock, etc. as an intermediate layer, non-woven fabric, leather, artificial leather, paper, etc. (skin material). In the layer of the raw cloth, the adhesive is injected from the back surface or the front surface, and the adhesive is cured by applying ultrasonic waves or high frequencies while compressing the injection point to bond the front surface layer, the intermediate layer, and the back surface layer. It is characterized in that a concave portion is formed by the above-mentioned material, and quilting is formed by repeating this process once or continuously.

The following Patent Document 2 proposes a waterproof quilt-like synthetic leather. In this synthetic leather, a urethane film is integrally adhered to a knitted ground on which threads are arranged using heat-shrinkable threads in a seam shape, and the adherend film surface of the seam-like arrangement portion of the threads is a seam. A recess is formed on the shape line, and a seam-like pattern is exposed on the surface of the adherend film.

Japanese Patent No. 3037948 Jitsufuku No. 3-7436

However, if the skin material is sewn after being overlapped with the cushioning material by adhesion as described above, the skin material will break at the stitches (seam) and corners will be formed, resulting in design softness. There was a drawback that it could not be expressed. This drawback is previously unrecognized.

Although it is not an object to solve the above-mentioned drawbacks, a method as disclosed in Patent Documents 1 and 2 has been proposed as a method for producing quilting in which stitches do not appear on the surface of the skin material.

However, the conventional processing methods disclosed in Patent Documents 1 and 2 have the following problems, and are the same as the conventional techniques in that none of them can express design softness.

That is, in the method disclosed in Patent Document 1, the surface layer or the back surface layer is adhered to the intermediate layer, or the surface layer or the back surface layer is superposed on the intermediate layer, and then the surface layer or the back surface layer is used. The adhesive is injected, and the quilting process is performed by curing the adhesive while compressing the injection site. However, after combining the skin material and the cushioning material, it is pressed from above the skin material with an ultrasonic adhesive having a flat tip to form a narrow recess of the width, so that the portion pressed by the ultrasonic adhesive is used. After all, a corner is formed between the surroundings.

Further, in the method disclosed in Patent Document 2, the thread shrinks by heating to form a recess, but since the recess is a single stitch (single stitch), the recess has no width and is located at the seam. The corners will come out. This point is also clear from FIG. 1 of Patent Document 2.

Therefore, in the methods disclosed in the prior art and Patent Documents 1 and 2, corners are formed at the boundary between the convex portion and the concave portion of the skin material, so that the softness of the shape finish in the design is impaired. There is a problem.

The present disclosure has focused on the above problems, and an object of the present disclosure is to provide a laminated molded product capable of enhancing the softness of a shapely finish in a design and a method for producing the same.

In the present inventor, the cause of the above problem is that in the conventional method, the skin is sewn on the cushioning material, so that the skin and the cushioning material are in close contact with each other, and the corners formed by compressing the cushioning material by sewing remain as they are. I found that it also appears on the front side of the skin material. Therefore, if the skin material does not completely adhere to the cushioning material and a gap is created at the corners at both ends of the recess of the cushioning material, the front side of the skin material becomes a gentle curved surface as a design. We thought that we could obtain a shape with a soft appearance. Therefore, the means for solving the problem is as follows.

The laminated molded product of the present disclosure includes a skin material layer, a cushioning material layer, and an adhesive layer. The skin material layer is made of a skin material. The cushioning material layer is made of a cushioning material. The adhesive layer is made of an adhesive and is provided between the skin material layer and the cushioning material layer. In the laminated molded product, the cushioning material layer has recesses, and both ends of the recesses of the cushioning material layer are provided with a pair of valleys. The cushioning material layer is broken at a portion corresponding to this valley portion to form a corner, and the portion sandwiched between the pair of valley portions is the bottom surface of the recess. The portion of the epidermis layer corresponding to the bottom surface of the recess sandwiched between the pair of valleys is convex downward in side view, that is, has a positive curvature. The bottom surface of the recess sandwiched between the valleys of the side surface where the adhesive layer is formed in the cushioning material layer is convex upward in the side view, that is, has a negative curvature or is flat. is there. Therefore, a gap is formed between the valley portion of the cushioning material layer and the skin material layer.

In the method for producing a laminated molded article of the present disclosure, a convex portion forming step, an adhesive layer forming step, a pressing step, and a convex portion reforming step are sequentially performed, so that the other surface of the skin material layer is viewed from the side. Convex downwards, i.e. have a positive curvature, and one surface of the cushioning layer is convex upwards, i.e., negative curvature or flat in side view. Form a shape that becomes. In the convex portion forming step, a convex portion is formed on one surface of the cushioning material layer made of the cushioning material. In the adhesive layer forming step, an adhesive layer made of an adhesive is formed on one surface of the skin material layer made of the skin material. In the pressing step, the skin material layer is pressed against one surface of the cushioning material layer at a predetermined pressure. In the convex portion reforming step, by releasing a predetermined pressure, one surface of the cushioning material layer is swelled by the restoring force of the cushioning material layer that has been pressed, and the convex portion is regenerated on one surface of the cushioning material layer. Form.

As a result, it is possible to provide a laminated molded product and a method for producing the same, which can enhance the softness of the shapely finish on the design.

It is a side sectional view which shows the schematic structure of the laminated molded body in Example 1 and Example 2. FIG. It is a photograph of the test product 1 produced by the procedure of the experimental example in Example 1 taken from the skin material layer 1 having a diamond pattern. It is a photograph of the test product 1 produced by the procedure of the experimental example in Example 1 taken from the second porous layer 41 having a diamond pattern. It is a side sectional view which shows the schematic structure of the test product 2 produced by the conventional procedure in the experimental example in Example 1. FIG. It is a photograph of the test product 2 produced by the conventional procedure in the experimental example of Example 1 taken from the skin material 21 having a diamond pattern. It is a photograph of the test product 2 produced by the conventional procedure in the experimental example of Example 1 taken from the non-woven fabric 24 having a diamond pattern. It is explanatory drawing which shows the mechanism which the quality deterioration occurs by the perforation processing in the laminated molded article of the comparative example of the laminated molded article in Example 2. It is explanatory drawing which shows the mechanism which the productivity decrease occurs by the perforation processing in the laminated molded article of the comparative example of the laminated molded article in Example 2. It is a side sectional view which shows the schematic structure of the laminated molded body in Example 3.

Hereinafter, the best mode for realizing the laminated molded article of the present disclosure and the method for producing the same will be described with reference to Examples 1 to 3 shown in the drawings.

First, the configuration will be described.
The laminated molded product in the first embodiment is applied to an interior product for a vehicle (for example, a vehicle seat or the like).

[Overall composition of laminated molded product]
FIG. 1 is a side sectional view showing a schematic configuration of the laminated molded product according to the first embodiment. Hereinafter, the overall configuration of the laminated molded product will be described with reference to FIG.

The laminated molded body 100 includes a skin material layer 1, a cushioning material layer 2, an adhesive layer 3, a porous layer 4, and a connecting portion 5. The laminated molded body 100 has recesses 2C in which the cushioning material layer 2 is compressed in the X direction, and has a pair of valleys 2V at both ends of the recesses 2C of the cushioning material layer 2.

The skin material layer 1 is made of a skin material (for example, cowhide). In the skin material layer 1, the portion corresponding to the convex portion 2T (recessed bottom surface portion) sandwiched between the pair of valley portions 2V of the cushioning material layer 2 is convex downward in side view, that is, is positive . Has a curvature.

The cushioning material layer 2 is made of a cushioning material (for example, urethane foam). The convex portion 2T sandwiched between the valley portions 2V of the surface 2A on the side where the second adhesive layer 31 is formed in the cushioning material layer 2 is convex upward in the side view, that is, has a negative curvature. Has . Protrusion 2T sandwiched between the valley portions 2V surface 2B of the slow third adhesive layer 32 in衝材layer 2 is formed side is viewed from the side, has a convex downward, i.e., positive Has a curvature. A cushioning material is provided between the surface 2A on the side where the second adhesive layer 31 is formed in the cushioning material layer 2 and the surface 1B on the side where the first adhesive layer 30 is formed in the skin material layer 1. A substantially triangular void 2Vh is formed in a portion of the layer 2 corresponding to the valley portion 2V in a side view. The gap 2Vh is a gap that forms an air flow in the Z direction.

The adhesive layer 3 is made of an adhesive (for example, a thermoplastic adhesive sheet). The adhesive layer 3 includes a first adhesive layer 30, a second adhesive layer 31, and a third adhesive layer 32. The first adhesive layer 30 is provided between the skin material layer 1 and the first porous layer 40. The second adhesive layer 31 is formed on one surface 2A of the cushioning material layer 2. The second adhesive layer 31 is provided between the first porous layer 40 and the cushioning material layer 2, and adheres the first porous layer 40 to the cushioning material layer 2. The third adhesive layer 32 is formed on the other surface 2B of the cushioning material layer 2. The third adhesive layer 32 is provided between the second porous layer 41 and the cushioning material layer 2, and adheres the second porous layer 41 to the cushioning material layer 2.

The porous layer 4 (for example, non-woven fabric) communicates the inside and the outside of the cushioning material layer 2. The porous layer 4 is a layer that forms an air flow in the Z direction. The porous layer 4 includes a first porous layer 40 and a second porous layer 41. The first porous layer 40 is formed on the surface 31A of the second adhesive layer 31 opposite to the side on which the cushioning material layer 2 is formed. The second porous layer 41 is formed on the surface 32A of the third adhesive layer 32 opposite to the side on which the cushioning material layer 2 is formed.

The connecting portion 5 (for example, stitch) connects the first porous layer 40, the second adhesive layer 31, the cushioning material layer 2, the third adhesive layer 32, and the second porous layer 41. The connecting portion 5 includes a first connecting portion 50 and a second connecting portion 51. The first connecting portion 50 and the second connecting portion 51 are provided at positions separated from each other in the Y direction. The separation distance D is preset to a predetermined length (for example, 5 mm or more) required to express the design of the laminated molded product 100. When the separation distance D is less than 5 mm, a corner is formed in the center of the recess 2C, so that a flexible design cannot be expressed. Further, when the separation distance D is long (for example, 15 mm or more), the center of the cushioning material recess is raised and the recess of the laminated molded body recess becomes shallow, so it is necessary to appropriately increase the number of stitches.

Experimental Example 1

Next, the present disclosure will be specifically described with reference to Experimental Example 1. Here, the experimental results of examining the design of the laminated molded product 100 (see FIG. 1) according to the present embodiment will be described. The present disclosure is not limited to this experimental example. More specifically, the present inventor has a test product of the laminated molded product 100 (hereinafter referred to as test product 1) and a test product of the conventional laminated molded product 200 (see FIG. 4) (hereinafter referred to as test product 2). An experiment was conducted to evaluate the design of both.

(About the production of test product 1)
The present inventor manufactured the parts on the lower back side and the back side of the cushion of the vehicle seat main material as the test product 1. First, genuine leather for vehicles was prepared as the skin material layer 1 (see FIG. 1). Here, the thickness of the genuine leather for vehicles was 1.2 ± 0.2 mm, and the BLC (rigidity and softness) of the genuine leather for vehicles was 33.8. A thermoplastic adhesive sheet was prepared as the first adhesive layer 30, the second adhesive layer 31, and the third adhesive layer 32. Defilmed urethane (t10, 0.03 g / cm ³ ) was prepared as the first porous layer 40 and the second porous layer 41. Urethane foam (t2, 50g, 0.022g / cm ³ ) was prepared as the cushioning material layer 2. A stitch for a computer sewing machine (AMS-224EN-420 (trade name) manufactured by JUKI) was prepared as the connecting portion 5.

Next, the second adhesive layer 31 was sandwiched between the cushioning material layer 2 and the first porous layer 40, and the third adhesive layer 32 was sandwiched between the cushioning material layer 2 and the second porous layer 41. .. Next, the surface 40A (see FIG. 1) on the side opposite to the side where the second adhesive layer 31 is formed in the first porous layer 40 and the third adhesive layer 32 are formed in the second porous layer 41. A press working was performed to press the surface 41A on the side opposite to the side on which the surface is. At that time, the conditions for press working were a temperature of 115 ° C., a pressure of 2000 kg / 0.6 m ² , and a working time of 10 seconds. By the press working, the cushioning material layer 2 and the first porous layer 40 were adhered by the second adhesive layer 31, and the cushioning material layer 2 and the second porous layer 41 were adhered by the third adhesive layer 32. Subsequently, in this experimental example, the convex portion forming step, the adhesive layer forming step, and the pressing step described later were performed in this order to prepare the test product 1.

(Convex forming process)
In the convex portion forming step, the first connecting portion 50 and the second are connected to the first porous layer 40, the second adhesive layer 31, the cushioning material layer 2, the third adhesive layer 32 and the second porous layer 41 by a computer sewing machine. A quilting process was performed using the connecting portion 51. By the quilting process, a convex portion 2T was formed on one surface 2A and the other surface 2B of the cushioning material layer 2. At that time, the condition of the quilting process was that the distance between the first connecting portion 50 and the second connecting portion 51 (separation distance D shown in FIG. 1) was at least 5 mm or more.

(Adhesive layer forming process)
In the next adhesive layer forming step, the first adhesive layer 30 is sandwiched between the first porous layer 40 that has been quilted in the convex portion forming step and the skin material layer 1. As a result, the first adhesive layer 30 was formed on one surface 1B (see FIG. 1) of the skin material layer 1.

(Pressing process)
In the next pressing step, the other surface 1A of the skin material layer 1 on which the first adhesive layer 30 is formed on one surface 1B in the adhesive layer forming step is pressed against the other surface 1A of the cushioning material layer 2 at a predetermined pressure. Pressed to press against. By the press working, the skin material layer 1 and the first porous layer 40 were adhered by the first adhesive layer 30. At that time, the conditions for press working were a temperature of 115 ° C., a pressure of 2000 kg / 0.6 m ² , and a working time of 30 seconds.

(Convex reshaping process)
In the next convex portion reforming step, by releasing a predetermined pressure (pressing pressure) in the press working of the pressing step, one of the cushioning material layers 2 is restored by the restoring force of the cushioning material layer 2 pressed by the pressing pressure. The surface 2A was swollen to reshape the convex portion 2T on one surface 2A of the cushioning material layer 2. As a result, the other surface 1A of the skin material layer 1 is convex downward in the side view, that is, has a positive curvature, and one surface 2A of the cushioning material layer 2 is in the side view. It formed a shape that was convex upward, that is, had a negative curvature (see FIG. 1). The gap 2Vh is formed so that the skin material 1 is separated from the surface 2A of the cushioning material layer 2 at the valley portion 2V of the surface 2A of the cushioning material layer 2 when the surface 2A of the cushioning material layer 2 swells due to the release of the press pressure. To.

(About the design of test product 1)
FIG. 2 is a photograph of the test product 1 produced by the above procedure taken from the diamond pattern-like skin material layer 1. FIG. 3 is a photograph of the test product 1 produced by the above procedure taken from the diamond pattern-like second porous layer 41.

As shown in FIG. 3, the present inventor sets the distance D between the first connecting portion 50 and the second connecting portion 51 to a predetermined length (for example, 5 mm) when the quilting process is performed in the convex portion forming step. By securing the above, we succeeded in improving the design of the laminated molded product 100. Specifically, after forming the convex portion 2T on one surface 2A of the cushioning material layer 2 in the convex portion forming step, the surface 1A of the skin material layer 1 is pressed toward the first porous layer 40 in the pressing step. By adhering the skin material layer 1 to the cushioning material layer 2, the cross-sectional shape of the skin material layer 1 is devised so as to have a gentle curved shape. As a result, as shown in FIG. 2, we succeeded in producing the softness of the shape finish on the diamond pattern-like design on the surface 1A of the skin material layer 1.

Further, in the test product 1, in the quilting process before adhering the skin material layer 1 and the cushioning material layer 2, only the cushioning material layer 2 is undulated, and then the skin material layer 1 is formed by the first adhesive layer 30. It was found that since it is adhered to the first porous layer 40, the degree of freedom of expression of undulations in the skin material layer 1 can be improved.

(About the production of test product 2)
FIG. 4 is a side sectional view showing a schematic configuration of the test product 2 produced by the conventional method. FIG. 5 is a photograph of the test product 2 produced by the above-mentioned conventional procedure taken from the diamond-patterned skin material 21. FIG. 6 is a photograph of the test product 2 produced by the above-mentioned conventional procedure taken from the non-woven fabric 24 having a diamond pattern.

The present inventor manufactured the parts on the lower back side and the back side of the cushion of the vehicle seat main material as the test product 2 by a conventional method (see FIG. 4). First, as shown in FIG. 4, the skin material 21 was adhered to one surface 22A of the urethane foam 22 with the first adhesive 23A. Next, the non-woven fabric 24 was adhered to the other surface 22B of the urethane foam 22 with the second adhesive 23B. Next, the skin material 21, the first adhesive 23A, the urethane foam 22, the second adhesive 23B, and the non-woven fabric 24 were quilted. As a result, the skin material 21, the first adhesive 23A, the urethane foam 22, the second adhesive 23B, and the non-woven fabric 24 were connected by the thread 25 to prepare the test product 2.

(About the design of test product 2)
In the laminated molded product 200 according to the test product 2, as shown in FIG. 4, the surface 21A of the skin material 21 opposite to the side on which the first adhesive 23A is formed is convex upward, that is, , Has a negative curvature. Therefore, an angle as shown in FIG. 4 is generated in the valley portion 21V of the surface 21A. Further, in the laminated molded product 200 according to the test product 2, as shown in FIG. 4, the surface 24A of the nonwoven fabric 24 opposite to the side on which the second adhesive 23B is formed is convex downward. That is, it has a positive curvature. Therefore, the valley portion 24V of the surface 24A also has an angle as shown in FIG. 4 as in the valley portion 21V.

As described above, due to the corners generated on the surface 21A of the skin material 21 and the corners generated on the surface 24A of the non-woven fabric 24, as shown in FIG. 5, the diamond pattern is formed on the surface 21A of the skin material 21 in the test product 2. It turned out that it was not possible to express the softness of the shape finish on the key design. Similarly, as shown in FIG. 6, it was found that in the test product 2, the surface 24A of the non-woven fabric 24 could not express the softness of the diamond-patterned design.

In the laminated molded body 100 of Example 1, the portion of the skin material layer 1 corresponding to the convex portion 2T sandwiched between the pair of valley portions 2V of the cushioning material layer 2 is convex downward in the side view. That is, it has a positive curvature. The convex portion 2T sandwiched between the valleys 2V of the surface 2A on the side where the second adhesive layer 31 (that is, the skin material layer 1) is formed in the cushioning material layer 2 is convex upward in the side view . That is, it has a negative curvature. That is, in the laminated molded body 100 of Example 1, the skin material layer 1 is cushioned by using the first adhesive layer 30 in a state where the cushioning material layer 2 below the skin material layer 1 is undulated in advance. Can be adhered to layer 2. For this reason, the portion of the surface 1A of the skin material layer 1 that becomes a valley of undulations does not have the conventional corners. As a result, the cross-sectional shape of the skin material layer 1 becomes a gentle curved surface shape. Therefore, when the laminated molded body 100 is attached to the vehicle seat, it is possible to enhance the visual effect of the softness of the shape finish on the design on the surface 1A of the skin material layer 1.

The second embodiment is an example in which the skin material layer 1 and the first adhesive layer 30 are perforated.

First, the configuration will be described.
The laminated molded product in the second embodiment is applied to an interior product for a vehicle (for example, a vehicle seat or the like) as in the first embodiment.

[Overall composition of laminated molded product]
FIG. 1 is a side sectional view showing a schematic configuration of the laminated molded product according to the second embodiment. FIG. 7 is a view of the laminated molded product of Example 2 as viewed from the skin material layer 1. Hereinafter, the overall configuration of the laminated molded product will be described with reference to FIG. Note that in FIG. 1, the perforation holes are not shown.

As shown in FIG. 1, the laminated molded body 100 includes a skin material layer 1, a cushioning material layer 2, an adhesive layer 3, a porous layer 4, and a connecting portion 5. The adhesive layer 3 includes a first adhesive layer 30, a second adhesive layer 31, and a third adhesive layer 32.

The skin material layer 1 and the first adhesive layer 30 are formed with perforation holes that penetrate the skin material layer 1 and the first adhesive layer 30 in the X direction and communicate with the void 2Vh. That is, in the second embodiment, the skin material for the seat for automobiles is designed, or for a vehicle equipped with an air-conditioning function, hot air and cold air are ventilated from the inside of the seat to the room depending on the sensible temperature or room temperature. Layer 1 is perforated.
Since the other configurations are the same as those in the first embodiment, the corresponding configurations are designated by the same reference numerals and the description thereof will be omitted.

(Mechanism of quality deterioration and productivity deterioration due to perforation processing)
FIG. 7 is an explanatory diagram showing a mechanism in which quality deterioration occurs due to perforation processing in the laminated molded product of the comparative example of the laminated molded product in Example 2. FIG. 8 is an explanatory diagram showing a mechanism in which a decrease in productivity due to perforation processing occurs in the laminated molded product of the comparative example of the laminated molded product in Example 2. Here, as for the parts that have been perforated as described above, there are parts that have been further quilted after the perforation. Hereinafter, the mechanism by which the quality deterioration and the productivity deterioration of the parts occur will be described with reference to FIGS. 7 and 8.

(Mechanism of quality deterioration caused by perforation processing)
As shown in FIG. 7, after perforation processing is performed on one surface 61A of the skin material 61, the skin material 61 and the urethane foam layer (not shown) are adhered and quilted. Therefore, as shown in the partially enlarged view of FIG. 7, the needle hole falls into the perforation hole 61H, and the stitch 65 has a zigzag shape. For this reason, there has been a problem that the quality is visually deteriorated.

(Mechanism of productivity decrease due to perforation processing)
Further, for the above improvement, as shown in FIG. 8, when the perforation hole 71H is adjusted in advance so as not to be opened in the vicinity of the stitch 75 for quilting, and the punched skin material 71 is quilted, the hole is formed. There is a problem that it is difficult to accurately aim at the centers of the 71H and the hole 71H for stitching. In addition, it takes time to perform such a special perforation process, and there is a problem that productivity is lowered.

On the other hand, in the laminated molded body 100 of the second embodiment, since the first connecting portion 50 and the second connecting portion 51 for quilting processing are lower than the skin material layer 1 as shown in FIG. Regardless of the quilted portion, the perforated skin material layer 1 can form a design having an undulating expression.

Further, in the laminated molded product 100 of Example 2, the skin material layer 1 and the first adhesive layer 30 are perforated so as to penetrate the skin material layer 1 and the first adhesive layer 30 in the X direction and communicate with the void 2Vh. Hole is formed. Therefore, in addition to being able to form an air passage in the Z direction by the void 2Vh, it is possible to form an air passage in the X direction by the perforation hole. As a result, the air permeability of the laminated molded product 100 can be further improved by the amount of the increase in the air passages in the X direction.

Example 3 is an example in which the cushioning material layer is formed by heat welding.

First, the configuration will be described.
The laminated molded product in the third embodiment is applied to an interior product for a vehicle (for example, a vehicle seat or the like) as in the first embodiment.

[Overall composition of laminated molded product]
FIG. 9 is a side sectional view showing a schematic configuration of the laminated molded product according to the third embodiment. Hereinafter, the overall configuration of the laminated molded product will be described with reference to FIG.

As shown in FIG. 9, the laminated molded product 300 includes a skin material layer 81, a cushioning material layer 82, and an adhesive layer 83. The laminated molded body 300 has recesses 82C in which the cushioning material layer 82 is compressed in the X direction, and has a pair of valleys 82V at both ends of the recesses 82C of the cushioning material layer 82.

The skin material layer 81 is made of a skin material (for example, cowhide). In the skin material layer 81, the portion corresponding to the flat portion 82F (recessed bottom surface portion) sandwiched between the pair of valley portions 82V of the cushioning material layer 82 is convex downward in side view, that is, is positive . Has a curvature.

The cushioning material layer 82 is made of a cushioning material (for example, urethane foam). The flat portion 82F sandwiched between the valley portions 82V of the surface 82A on the side where the adhesive layer 83 is formed in the cushioning material layer 82 is a flat portion in a side view. Similarly, the flat portion 82F sandwiched between the valley portions 82V of the surface 82B on the side opposite to the side where the adhesive layer 83 is formed in the cushioning material layer 82 is a flat portion in the side view. The pair of valley portions 82V are provided at positions separated in the Y direction. The separation distance D1 is set in advance to a predetermined length (for example, 5 mm or more) necessary for expressing the design of the laminated molded product 300. The valley of the cushioning material layer 82 is between the surface 82A on the side where the adhesive layer 83 is formed in the cushioning material layer 82 and the surface 81B on the side where the adhesive layer 83 is formed in the skin material layer 81. A substantially triangular void 82Vh is formed in a portion corresponding to the portion 82V in a side view. The gap 82Vh is a gap that forms an air flow in the Z direction.

In Example 3, the cushioning material layer 82 is formed by heat welding. The heat welding is performed by applying a welder process to the cushioning material layer 82.

The adhesive layer 83 is made of an adhesive (for example, a thermoplastic adhesive sheet). The adhesive layer 83 is provided between the skin material layer 81 and the cushioning material layer 82, and adheres the skin material layer 81 to the cushioning material layer 82.

Experimental Example 2

Next, the present disclosure will be specifically described with reference to Experimental Example 2. Here, the experimental results of examining the design of the laminated molded product 300 (see FIG. 9) according to the present embodiment will be described. The present disclosure is not limited to this experimental example. More specifically, the present inventor conducted an experiment to evaluate the design of both the test product 2 and the test product of the laminated molded product 300 (hereinafter referred to as the test product 3).

(About the production of test product 3)
The present inventor produced the parts on the lower back side and the back side of the cushion of the vehicle seat main material as the test product 3. First, genuine leather for vehicles was prepared as the skin material layer 81 (see FIG. 9). Here, the thickness of the genuine leather for vehicles was 1.2 ± 0.2 mm, and the BLC (rigidity and softness) of the genuine leather for vehicles was 33.8. A thermoplastic adhesive sheet was prepared as the adhesive layer 83. Urethane foam (t2, 50 g, 0.022 g / cm ³ ) was prepared as the cushioning material layer 82.

Subsequently, in this experimental example, the convex portion forming step, the adhesive layer forming step, and the pressing step were performed in this order to prepare the test product 3.

(Convex forming process)
In the convex portion forming step, the cushioning material layer 82 was welded. At that time, the conditions for welding were that the current was 0.35 A, the welding time was 3.0 seconds, the cooling time was 3.0 seconds, and the mold temperature was 90 ° C. By the welding process, the cushioning material layer 82 was formed, and the convex portion 82T was formed on one surface 82A and the other surface 82B of the cushioning material layer 82. At that time, the conditions for welder processing were that the distance between the pair of valley portions 82V (separation distance D1 shown in FIG. 9) was at least 5 mm or more.

(Adhesive layer forming process)
In the next adhesive layer forming step, the adhesive layer 83 is sandwiched between the cushioning material layer 82 that has been welded in the convex portion forming step and the skin material layer 81. As a result, the adhesive layer 83 was formed on one surface 81B (see FIG. 9) of the skin material layer 81.

(Pressing process)
In the next pressing step, the other surface 81A of the skin material layer 81 on which the adhesive layer 83 is formed on one surface 81B in the adhesive layer forming step is pressed against one surface 82A of the cushioning material layer 82 with a predetermined pressure. Pressed. By the press working, the skin material layer 81 and the cushioning material layer 82 were adhered by the adhesive layer 83. At that time, the conditions for press working were a temperature of 115 ° C., a pressure of 2000 kg / 0.6 m ² , and a working time of 30 seconds.

(Convex reshaping process)
In the next convex portion reforming step, by releasing a predetermined pressure (press pressure) in the press working of the pressing step, one of the cushioning material layers 82 is restored by the restoring force of the cushioning material layer 82 pressed by the pressing pressure. The surface 82A was swollen to form a gap 82Vh, and the convex portion 82T was reformed on one surface 82A of the cushioning material layer 82. As a result, the other surface 81A of the skin material layer 81 is convex downward in the side view, that is, has a positive curvature, and one surface 82A of the cushioning material layer 82 is in the side view. It was formed into a flat shape (see FIG. 9).

(About the design of test product 3)
The present inventor has determined to improve the design of the laminated molded body 300 by ensuring a gap D1 between the pair of valley portions 82V of 5 mm or more when the quilting process is performed in the convex portion forming step. Successful. Specifically, after forming the convex portion 82T on one surface 82A of the cushioning material layer 82 in the convex portion forming step, the surface 81A of the skin material layer 81 is pressed toward the cushioning material layer 82 in the pressing step to press the skin. By adhering the material layer 81 to the cushioning material layer 82, the cross-sectional shape of the skin material layer 81 was devised so as to have a gentle curved shape. As a result, we succeeded in producing a softer design-like finish on the surface 81A of the skin material layer 81 as compared with the test product 2.

Further, in the test product 3, in the welding process before adhering the skin material layer 81 and the cushioning material layer 82, only the cushioning material layer 82 is undulated, and then the skin material layer 81 is cushioned by the adhesive layer 83. Since it is adhered to the layer 82, it was found that the degree of freedom of expression of undulations in the skin material layer 81 can be improved as compared with the test product 2.

Further, in the laminated molded body 300 of Example 3, the cushioning material layer 82 is formed by heat welding by welding, and a convex portion 82T is formed on one surface 82A and the other surface 82B of the cushioning material layer 82. Therefore, it is very advantageous in terms of cost as compared with the case where the cushioning material layer 82 is formed by, for example, sewing. Specifically, in the case of molding by sewing, it is necessary to prepare a mold for foam molding according to the design of the cushioning material layer 82, but in the case of processing by heat welding, the portion where the cushioning material layer 82 is recessed. It is only necessary to prepare the mold of the above, which is very advantageous in terms of cost. Further, in the case of processing by heat welding as compared with molding by cutting, the process is not complicated and it is very advantageous in terms of cost.

Although the laminated molded article and the manufacturing method thereof of the present disclosure have been described above based on Examples 1, 2 and 3, the specific configuration is not limited to these Examples. As long as the gist of the invention according to each claim is not deviated from the claims, design changes and additions are permitted.

In Examples 1 and 2, an example was shown in which the cushioning material layer 2 under the skin material layer 1 was formed of quilted urethane foam. However, it is not limited to this. For example, the cushioning material layer 2 may be molded urethane foam (heat welding, foaming in a mold, cutting, etc.). Further, for example, the cushioning material layer 2 may be quilted cotton. In this case, if the hardness of the molded urethane foam can be maintained at a hardness that does not lose its shape by cutting, the laminated molded product 100 is formed by cutting the urethane foam without quilting the urethane foam. May be decorated. When the urethane foam itself is cut, it is not necessary to provide the cushioning material layer 2 with the first porous layer 40 that prevents the urethane foam from being torn when the urethane foam is sewn by stitching. Further, even if the urethane foam is soft, when the urethane foam itself is cut to decorate the laminated molded body 100, the first porous layer 40 for preventing the urethane foam from tearing or the like is used as the cushioning material layer 2. It does not have to be provided.

In Example 1 and Example 2, an example in which the skin material layer 1 is formed of cowhide is shown, and in Example 3, an example in which the skin material layer 81 is formed of cowhide is shown. However, it is not limited to this. For example, the skin material layer 1 or the skin material layer 81 may be any one of genuine leather, synthetic leather, artificial leather, polyvinyl chloride (PVC) and cloth.

In Example 1 and Example 2, an example in which the porous layer 4 is formed of a non-woven fabric is shown. However, it is not limited to this. For example, the porous layer 4 may be a mesh material. In short, the porous layer 4 may be a material that communicates the inside and the outside of the cushioning material layer 2.

In Example 1 and Example 2, an example of forming a diamond-like handle on the skin material layer 1 and the second porous layer 41 was shown. However, it is not limited to this. For example, a linear border pattern or a curved pattern may be formed on the skin material layer 1 and the second porous layer 41. In short, the handle formed on the skin material layer 1 and the second porous layer 41 only needs to have a soft finish in terms of design.

In Example 1, Example 2, and Example 3, an example in which the laminated molded article of the present disclosure and the manufacturing method thereof are applied to a vehicle seat is shown. However, it is not limited to this. The laminated molded article and the manufacturing method thereof of the present disclosure can also be applied to automobile interior parts such as instrument panels, door trims and seat backs.

In Example 1, Example 2, and Example 3, an example in which the laminated molded article of the present disclosure and the manufacturing method thereof are applied to an interior product for a vehicle such as an automobile is shown. However, the laminated molded article and its manufacturing method of the present disclosure can also be applied to interior parts and furniture (for example, leather sofas, etc.) of vehicles other than vehicles (for example, railroad vehicles, pleasure boats, etc.). ..

In the first embodiment, the separation distance D between the first connecting portion 50 and the second connecting portion 51 is set to 5 mm or more, and in the third embodiment, the separation distance D1 of the pair of valley portions 82V is set to 5 mm or more. showed that. However, it is not limited to this. For example, the separation distances D and D1 may be set to less than 5 mm. In short, the separation distances D and D1 may be set to the lengths necessary for expressing the designs of the laminated molded bodies 100 and 300, respectively.

Cross-reference to related applications

This application claims priority under Japanese Patent Application No. 2016-22709 filed with the Japan Patent Office on November 22, 2016, the entire disclosure of which is incorporated herein by reference in its entirety.

1, 81 Cushioning material layer 1A Surface 1L on the side opposite to the side where the first adhesive layer 30 is formed in the cushioning material layer 1B Surface 1L on the side where the first adhesive layer 30 is formed in the cushioning material layer 1 Folded portion 2, 82 Cushioning material layer 2A Surface 2C on the side where the second adhesive layer 31 is formed in the cushioning material layer 2B Surface 2C on the side where the third adhesive layer 32 is formed in the cushioning material layer 2. 82C Concave 2T Convex (recess bottom)
2V, 82V Valley 2Vh, 82Vh Voids 3, 83 Adhesive layer 4 Porous layer 5 Connecting part 30 First adhesive layer 31 Second adhesive layer 32 Third adhesive layer 40 First porous layer 41 Second porous layer 50 1st connecting portion 51 2nd connecting portion 81A Surface 81B on the side opposite to the side where the adhesive layer 83 is formed in the skin material layer 81 B Surface 82A buffer on the side where the adhesive layer 83 is formed in the skin material layer 81 Surface 82B on the side where the adhesive layer 83 is formed in the material layer 82 B Surface 82F flat portion (bottom surface portion of the recess) on the side opposite to the side where the adhesive layer 83 is formed in the cushioning material layer 82
100, 300 laminated molded parts

Claims (5)

The epidermis material layer made of epidermis material and
A cushioning material layer made of cushioning material and
It is made of an adhesive and includes an adhesive layer provided between the skin material layer and the cushioning material layer.
The cushioning material layer has a recess,
The recess of the cushioning material layer has a pair of valleys and
The portion of the epidermis layer corresponding to the bottom surface of the recess sandwiched between the pair of valleys has a positive curvature in side view.
The bottom surface of the recess sandwiched between the valleys on the surface of the cushioning material layer on the side on which the adhesive layer is formed has a negative curvature or is flat in a side view. Molded body. In the laminated molded article according to claim 1,
A laminated molded product comprising a porous layer provided between the adhesive layer and the cushioning material layer. In the laminated molded article according to claim 2,
A laminated molded product, wherein the porous layer is any one of a non-woven fabric and a mesh material. In the laminated molded article according to any one of claims 1 to 3.
Between the surface of the skin material layer on which the adhesive layer is formed and the surface of the cushioning material layer on which the adhesive layer is formed, a valley portion of the cushioning material layer is formed. A laminated molded body characterized in that voids are formed in a corresponding portion in a side view. A convex portion forming step of forming a convex portion on one surface of a cushioning material layer made of a cushioning material,
An adhesive layer forming step of forming an adhesive layer made of an adhesive on one surface of the skin material layer made of the skin material,
A pressing step of pressing the skin material layer against one surface of the cushioning material layer with a predetermined pressure,
By releasing the predetermined pressure, one surface of the cushioning material layer is swelled by the restoring force of the cushioning material layer that has been pressed, and a convex portion is formed on one surface of the cushioning material layer. By performing the part reforming steps in order,
The other surface of the epidermis layer has a positive curvature in lateral view and
A method for producing a laminated molded product, wherein one surface of the cushioning material layer forms a shape having a negative curvature or becoming flat in a side view.

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